Unicoat Roofing has successfully completed a comprehensive roof restoration for a packaging company in Greeneville, Tennessee. The project, which covered 160,000 square feet of a standing seam metal roof, addressed severe leaks and deterioration that had been affecting the facility. Over an 80-day period, Unicoat worked meticulously to resolve these issues, ensuring that the facility could resume operations without the risk of further water damage.

Project Overview: Initial Challenges

The standing seam metal roof of the packaging facility had significant wear and tear due to aging. Many fasteners had backed out, causing gaps in the roof’s horizontal seams. Additionally, the facility’s skylights had developed open gaps, resulting in leaks. These leaks created severe challenges for the company, as several sections of the building became unusable due to water infiltration. In fact, some of the company’s expensive equipment had to be moved to avoid damage, further disrupting operations.

The Unicoat Solution: Advanced Sealing and Protection

To address these challenges, Unicoat Roofing implemented a multi-step restoration process, starting with the replacement of all loose or rusted fasteners. Ensuring the fasteners were secure was critical to preventing further leaks during the cleaning and sealing process.

After replacing the fasteners, the roof was pressure washed to remove any debris, dirt, or rust, preparing the surface for the next steps. Given the presence of rust in certain areas, a rust inhibitive primer was applied to prevent further corrosion, safeguarding the structural integrity of the metal roof.

Once the surface was properly prepared, Unicoat sealed all fastener penetrations and horizontal seams with a flashing-grade acrylic sealant. This step was crucial in reinforcing the vulnerable areas of the roof, ensuring that no water could penetrate these previously problematic zones.

To complete the restoration, two coats of Uniflex Acrylic were sprayed at a rate of 1.5 gallons per 100 square feet. This acrylic coating not only provides long-lasting waterproofing but also helps enhance the roof’s energy efficiency by reflecting sunlight and reducing heat absorption. The white coating will help keep the building cooler during the summer months, contributing to energy savings over time.

Skylight Safety and Compliance

An additional focus of the project was ensuring that the skylights were properly secured and safe. Prior to the restoration, the gaps in the skylights posed a safety and leakage risk. To prevent further incidents, Unicoat followed OSHA safety guidelines, installing protective cages around each skylight. These cages not only prevent accidental falls but also contribute to maintaining the integrity of the roof by protecting the vulnerable skylight areas.

Results and Long-Term Benefits

The restoration of the packaging facility’s roof has provided the company with a long-term solution to its leakage issues. The combination of fastener replacement, seam sealing, and the application of Uniflex Acrylic has created a durable, weather-resistant roof capable of withstanding Greeneville’s climate. Additionally, the use of a rust-inhibitive primer ensures that the metal roof will not succumb to corrosion in the foreseeable future.

Unicoat Roofing’s swift and efficient restoration process has allowed the packaging company to regain use of its entire facility without worrying about water damage. The project is a prime example of how Unicoat’s expertise in metal roof restoration can transform aging, problematic roofs into reliable, energy-efficient systems.

Conclusion: Unicoat Roofing’s Expertise on Display

The successful completion of this 160,000-square-foot project in Tennessee demonstrates Unicoat Roofing’s ability to handle complex roofing challenges while adhering to strict safety standards. From securing fasteners to sealing seams and protecting skylights, Unicoat ensured that every aspect of the roof was addressed with precision. This project highlights Unicoat’s commitment to providing high-quality, long-lasting roofing solutions that safeguard both buildings and businesses.